High Performance Electric Machine for Hybrid, Electric, and Fuel Cell Vehicle: Electromagnetic Design and Analysis

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Khwaja Rahman, GM Powertrain

Abstract

General Motors (GM) is actively working on developing electric vehicle (EV), hybrid vehicle (HEV), plug-in hybrid vehicle (PHEV), extended range electric vehicle (EREV), and fuel cell electric vehicle (FCEV) over the past several decades. GM has already brought several electrified production vehicles in the market such as the EV1 battery electric vehicle (BEV), Chevrolet Tahoe HEV, Gen1 and Gen2 Chevrolet Volt extended range electric vehicle (EREV), Gen1 Chevrolet Spark, and Gen2 Chevrolet Bolt BEV etc. To support all these already in production and upcoming electrified vehicles, GM has a very strong electric motor electromagnetic (EM) and mechanical design group, test and validation group, as well as prototype build and manufacturing group. This has given GM a unique opportunity to innovate and develop state of the art electric machines. Over the years GM has innovated and patented numerous EM and mechanical design and manufacturing techniques which have rolled into production vehicles. This presentation gives a retrospective of electric motor developments in GM for EV, HEV, PHEV, and FCEV. This talk includes i) the progression of EM design methodologies that gradually improved motor torque, power, and efficiency performance while mitigating for noise, ii) mechanical design techniques that lowers rotor stress, reduces manufacturing complexity, and lowers cost, iii) manufacturing techniques that comes up with innovative manufacturing methods to improve motor life as well as reduces cost etc.

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